Stretch laminate having novel adhesive pattern and methods of making the same

ABSTRACT

A stretch laminate having a first nonwoven material, a second nonwoven material, an elastic film. The elastic film has a first longitudinal side edge and a second longitudinal side edge. The stretch laminate further has a first plane of adhesive having differing amounts of adhesive as measured laterally within the stretch laminate. The differing amounts of adhesive being controllable. The first plane of adhesive being interposed between the first nonwoven material and the elastic film. The stretch laminate further has a second plane of adhesive having differing amounts of adhesive as measured laterally within the stretch laminate. The differing amounts of adhesive being controllable. The second plane of adhesive being interposed between the second nonwoven material and the elastic film. Each of the above elements are substantially laminated together to form a laminate. The laminate is activated to form the stretch laminate.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. Nonprovisional applicationSer. No. 11/298,025, filed Dec. 8, 2005, which claims the benefit ofU.S. Provisional Application No. 60/634,157 filed Dec. 8, 2004, thedisclosure of which is hereby incorporated by reference as if set forthin its entirety herein.

FIELD OF THE INVENTION

The present invention relates to stretch laminates having novel adhesivepatterns, and the apparatus and methods for making the same. Moreparticularly, the present invention relates to stretch laminates havingnovel adhesive patterns providing improved activation characteristics.

BACKGROUND

Stretch laminates are commonly used in the consumer-products industry.For example, stretch laminates are used in the manufacturing ofdisposable absorbent articles, such as disposable diapers. Conventionalstretch laminates often comprise of at least two nonwoven materialshaving at least one elastic film sandwiched therebetween. In themanufacturing of such conventional laminates, the use of adhesive isoften employed.

FIG. 1 a shows a schematic of a conventional manufacturing process 1000for the making of conventional stretch laminates. A first web ofnonwoven material 10 is supplied in a direction as indicated by arrow11. Adhesive 20 is applied to said first nonwoven 10 by way of anadhesive applicator 22. A second web of nonwoven material 12 is suppliedin a direction as indicated by arrow 13. Adhesive 21 is applied to saidsecond nonwoven 12 by way of an adhesive applicator 23. A web of elasticfilm 30 is supplied in a direction as indicated by arrow 31. These threewebs of materials are sandwiched together between combining rolls 70,72. Said combining rolls rotate in a direction as indicated by arrows71, 73, respectively. Once these three webs of materials are sandwichedtogether, they are subsequently activated between activation rolls 80,82. Said activation rolls rotate in a direction as indicated by arrows81, 83, respectively. Activation of said webs by way of activation rolls80, 82 is sometimes referred to as “ring rolling”. After saidactivation, the resulting product is a stretch laminate 99.

FIG. 1 b shows the applicator adhesive 22 from that of FIG. 1 a.Adhesive applicator 22 may comprise of a manifold 24, an adhesive inlet25 and a slot 26. Referring now to FIG. 1 c slot 26 may comprise of abackplate 27, shim 28 and a front plate 29. Referring now to FIG. 1 d,an exploded view of slot 26 is shown. As can be seen, backplate 27 maycomprise of a plurality of adhesive inlet ports 27 a. Adhesive may beintroduced into slot 26 through said adhesive inlet ports. Said adhesivemay then exit through adhesive outlet port 27 b, whereupon the adhesivewill come into contact with shim 28. Shim 28 may consist of multipleregions including a closed portion 28 c, an open portion 28 o and apartitioned section 28 f. The functionality of these various regionswill be discussed later.

FIG. 1 e shows the exemplary shim 28 from that of FIG. 1 d. Further, anexemplary deposition of adhesive is shown having exited through shim 28.For instance, adhesive intended to be placed between said first andsecond nonwoven materials and also laterally outboard of elastic film 30is identified as 20 n. Additionally, an adhesive intended to be placedbetween said first and second nonwoven materials and also on theoutboard edges of elastic film 30 is identified as 20 t. Finally, anadhesive intended to be placed between said first and second nonwovenmaterials and also laterally positioned inboard the edges of elasticfilm 30 is identified as 20 f. Referring now to FIG. 1 f, across-sectional view of the adhesive deposition patterned from FIG. 1 eis shown. As can be appreciated from this cross-sectional view, theadhesive within the region intended to be placed above or below elasticfilm 30 is discontinuous while the adhesive in the other regions iscontinuous. As is also depicted in this figure, and as experiencedthrough conventional use, supplying adhesive in this manner (i.e. via asingle source of adhesive supply) does not properly yield continuousregions of adhesive having varying and controllable amounts. Theimportance of such inadequacy within the prior art will be furtherexamined later.

FIG. 1 g shows the first web of nonwoven material 10 having regions ofadhesive. For example, a full coverage of adhesive 20 is applied in theareas surrounding the subsequent placement of elastic film 30. In theareas which will be underneath the subsequent placement of elastic film30, a partial coverage of adhesive 20 f is applied. In this particularexample, a series of parallel lines of adhesive is applied. Similar tothe first web of nonwoven material 10, the second web of nonwovenmaterial 12 also has regions of adhesive. For example, a full coverageof adhesive 21 n is applied in the areas surrounding the subsequentplacement of elastic film 30. In the areas which will be underneath thesubsequent placement of elastic film 30, a partial coverage of adhesive21 f is applied. In this particular example, a series of parallel linesof adhesive is applied. As is also shown in this conventionalembodiment, two webs of elastic film 30, are aligned with said parallellines of adhesive 20 f, 21 f. Partial application of adhesive in thismanner is important because these regions will be subjected to ringrolling as discussed above; therefore, these regions of material must besufficiently elastic so as not to create pinholes. The areas of fullcoverage, 20 n, 21 n will not be significantly activated, rather theseareas of full coverage provide for maximum adherence of first and secondnonwoven materials.

FIG. 2 a shows another exemplary slot 26 having a backplate 27, shim 28and frontplate 29. Similar to that of the slot shown in FIG. 1 d,backplate 27 as adhesive inlet ports 27 a. However, within thisparticular example, shim 28 does not contain partitioned regions; rathershim 28 contains only open regions 27 o and closed regions 28 c.Referring now to FIG. 2 b, the corresponding adhesive deposition forshim 28 of FIG. 2 a is provided. As can be appreciated, said depositionof adhesive is continuous along the entire cross-section of adhesive(see FIG. 2 c). And while shim 28 contains open regions 27 o havingvarying heights, the resulting adhesive deposition (as shown in FIG. 2c) does not have complementary variations in amount which arecontrollable because of the inadequacies of supplying adhesive in themanner as shown (e.g., use of a single adhesive supply supplyingadhesive via a single inlet). Referring now to FIG. 2 d, a first web ofnonwoven material 10 having regions of adhesive is shown. Within thisparticular example, a full coverage of adhesive is applied throughout,unlike the example in FIG. 1 g. Similar to the first web of nonwovenmaterial 10, the second web of nonwoven material 12 also has a fullcoverage of adhesive 20. Full coverage of adhesive in this mannerpresents several technical difficulties including pinholes duringactivation.

FIG. 3 a illustrates a cross-sectional view of the conventional stretchlaminate 99 from FIG. 1 g. As can be seen, a first web of nonwovenmaterial 10 is shown at the base of said laminate and a second web ofnonwoven material 12 is shown at the top of said laminate. In thisparticular example, two elastic films 30 are shown in spacialrelationship with each other and sandwiched between said webs ofnonwoven material. A first plane of adhesive is shown between said firstweb of nonwoven material 10 and said elastic film 30. Within said firstplane of adhesive are distinct regions of adhesive, namely, continuousapplication of adhesive 20 n and discontinuous application of adhesive20 f. The continuous application of adhesive 20 n is substantiallylocated near the ends and outside of elastic film 30. The discontinuousapplication of adhesive 20 f is substantially located between the endsof elastic film 30. Similarly, a second plane of adhesive is shownbetween said second web of nonwoven material 12 and said elastic film30. Within said second plane of adhesive are distinct regions ofadhesive, namely, continuous application of adhesive 21 n anddiscontinuous application of adhesive 21 f. The continuous applicationof adhesive 21 n is substantially located near the ends and outside ofelastic film 30. The discontinuous application of adhesive 21 f issubstantially located between the ends of elastic film 30.

FIG. 3 b shows the cross-sectional view of FIG. 3 a with particularemphasis on the continuous application of adhesive 20 n, 21 n. One ofthe primary purposes of application of adhesive within these regions isthe proper lamination of first and second webs of nonwoven materials. Ascan be seen and appreciated, however, in the areas in which elastic film30 is not present. There exists, a redundant supply of adhesive 20 n, 21n. More importantly, it is often a problem of the prior art that thisredundant supply of adhesive will penetrate the first and/or second websof nonwoven materials. Thus causing performance and/or aesthetic issues.For this reason, the amount of adhesive applied in these first andsecond planes of adhesive is often kept below a fixed maximum value soas to minimize bleed through and above a fixed minimum value so as toprovide sufficient adhesive for lamination.

FIG. 3 c shows the cross-sectional view of FIG. 3 a with particularemphasis on the continuous application of adhesive 20 t, 21 t within theareas identified with the letter “T”. These areas of adhesive, which arelocated at the ends of elastic film 30, are often referred to astackdown areas. Because this area of adhesive serves the primary purposeof tacking down the elastic film 30 into place, a sufficient amount ofadhesive must be supplied. Unlike the areas of adhesive outside ofelastic film 30, these tack down areas gain the benefit of the presenceof elastic film 30 such that bleeding of adhesive through first andsecond web of nonwoven material is not a major concern. Unfortunately,the designs of conventional stretch laminates and their respectivemanufacturing processes do not provide proper means for applyingdiffering amounts of adhesive to address the competing interests ofbleed through and sufficient tack down.

FIG. 3 d shows the cross-sectional view of FIG. 3 a with particularemphasis on the discontinuous application of adhesive 20 f, 21 f withinthe areas identified with the letter “F”. These areas of adhesive, whichare located between the ends of elastic film 30 is applied in adiscontinuous pattern so as to provide for sufficient elasticity ofelastic film 30 during activation. Even though the adhesive applied inthese areas is discontinuous, attempts to provide for sufficient tackdown and lamination often results in too much adhesive being appliedwithin these regions. Thus causing pinholes during activation.

FIG. 3 e shows a schematic of an exemplary ring rolling processinvolving a first activation roll 80 having protruding teeth and asecond activation roll 82 having protruding teeth, which mates those ofsaid first activation roll. While in reality the teeth of first andsecond activation rolls 80, 82 are positioned in an engaging manner,this schematic shows said rules being separated so as to show the properorientation and alignment of stretch laminate 99 in relationship to saidrules. As can be seen and appreciated, the discontinuous application ofadhesive 20 f, 21 f are significantly located between said teeth whilethe continuous application of adhesive 20 n, 21 n are not significantlylocated between said teeth. Such orientation and alignment is commonthroughout the industry.

FIG. 4 a shows a cross-sectional view of another exemplary, conventionalstretch laminate 99. In this particular example, the first and secondplane of adhesive application 20 n, 21 n is entirely continuous. Thisconventional stretch laminate may be easier to manufacture, thus perhapscheaper; however, the problems of pinholes during activation (see FIG. 4b) may be more prevalent. This type of conventional stretch laminate isoften used in applications wherein material barrier properties is notcritical

What is needed is a stretch laminate having differing amounts ofadhesive so as to properly be activated. The present invention describessuch a product and method of making the same.

SUMMARY OF THE INVENTION

A stretch laminate having a first nonwoven material, a second nonwovenmaterial, an elastic film. The elastic film may be interposed betweensaid first and second nonwoven material. The elastic film has a firstlongitudinal side edge and a second longitudinal side edge. The stretchlaminate further has a first plane of adhesive having differing amountsof adhesive as measured laterally within the stretch laminate. Thediffering amounts of adhesive being controllable. The first plane ofadhesive being interposed between the first nonwoven material and theelastic film. The stretch laminate further has a second plane ofadhesive having differing amounts of adhesive as measured laterallywithin the stretch laminate. The differing amounts of adhesive beingcontrollable. The second plane of adhesive being interposed between thesecond nonwoven material and the elastic film. Each of the aboveelements are substantially laminated together to form a laminate. Thelaminate is activated to form the stretch laminate.

Further, the first plane of adhesive may have (1) a first portion ofadhesive being laterally located between said first and secondlongitudinal side edges of said elastic film, said first portion ofadhesive being defined as film adhesive, (2) a second portion ofadhesive being laterally located near at least one longitudinal sideedge of said elastic film, said second portion of adhesive being definedas tackdown adhesive and (3) a third portion of adhesive being laterallylocated outboard of said longitudinal edges of said elastic film, saidthird portion of adhesive being defined as nonwoven adhesive. The filmadhesive may be discontinuous. The film adhesive may be continuous andhave an application amount less than that of said tackdown adhesive. Thenonwoven adhesive may have an application amount less than that of saidtackdown adhesive. All of the above may hold true for the second planeof adhesive.

A method for making the stretch laminate of the present invention whichincludes at least one adhesive applicator having a plurality of shims.The plurality of shims may be designated for application of either filmadhesive, tackdown adhesive or nonwoven adhesive. Such method mayinclude the use of a plurality of adhesive supplies to providedesignated adhesive to the plurality of shims which are designated forapplication of either film adhesive, tackdown adhesive or nonwovenadhesive.

Another exemplary stretch laminate in accordance with the presentinvention includes a first nonwoven material, a second nonwoven materialand an elastic film. The elastic film being interposed between saidfirst and second nonwoven material, said elastic film having a firstlongitudinal side edge and a second longitudinal side edge. The laminatefurther having (1) a first plane of adhesive, said first plane ofadhesive being interposed between said first nonwoven material and saidelastic film; (2) a second plane of adhesive, said second plane ofadhesive being interposed between said second nonwoven material and saidelastic film, wherein said first and second plane of adhesive havediffering amounts of adhesive from each other as measured laterallywithin the stretch laminate, said differing amounts of adhesive beingcontrollable; (3) a third plane of adhesive, said third plane ofadhesive being interposed between said second nonwoven material and saidelastic film; and (4) a fourth plane, said fourth plane of adhesivebeing interposed between said second nonwoven material and said elasticfilm, wherein said third and fourth plane of adhesive have differingamounts of adhesive from each other as measured laterally within thestretch laminate, said differing amounts of adhesive being controllable.Each of the above elements being substantially laminated together toform a laminate. The laminate is activated to form the stretch laminate.

BRIEF DESCRIPTION SHOWN IN THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter that is regarded as thepresent invention, it is believed that the invention will be more fullyunderstood from the following description taken in conjunction with theaccompanying drawings. None of the drawings are necessarily to scale.

FIG. 1 a shows a conventional manufacturing process for the making ofconventional stretch laminates;

FIG. 1 b shows a conventional adhesive applicator which is used in themanufacturing process of FIG. 1 a;

FIG. 1 c shows a cross-sectional view of the conventional adhesiveapplicator of FIG. 1 b;

FIG. 1 d shows an exploded view of the conventional adhesive applicatorof FIG. 1 b;

FIG. 1 e is a schematic of an exemplary adhesive deposition pattern forthat of the conventional adhesive applicator of FIG. 1 d;

FIG. 1 f shows a cross-sectional view of the exemplary adhesivedeposition pattern of FIG. 1 e;

FIG. 1 g shows a first and second web of nonwoven material havingadhesive; a first and second elastic film is shown interposed said firstand second web of nonwoven material to illustrate the alignment of thesubsequently made stretch laminate;

FIG. 2 a shows another exemplary exploded view of an alternate adhesiveapplicator design, namely, the shim consists of open and closed portionswithout the use of partitioned portions;

FIG. 2 b is a schematic of an exemplary adhesive deposition pattern ofFIG. 2 a;

FIG. 2 c shows a cross-sectional view of the exemplary adhesive patternof FIG. 2 b;

FIG. 2 d shows a first and second web of nonwoven material with adhesiveapplied over the entire surface; a first and second elastic film isinterposed between said first and second web of nonwoven material toillustrate the alignment of subsequently made stretch laminates;

FIG. 3 a shows a cross-sectional view of a conventional stretchlaminate;

FIG. 3 b shows a cross-sectional view of the conventional stretchlaminate of FIG. 3 a with particular emphasis on adhesive appliedlaterally outboard of the elastic film;

FIG. 3 c shows a cross-sectional view of the conventional stretchlaminate of FIG. 3 a with particular emphasis on adhesive applied nearthe ends of the elastic film;

FIG. 3 d shows a cross-sectional view of the stretch laminate of FIG. 3a with particular emphasis on the adhesive applied laterally in board ofthe ends of the elastic film;

FIG. 3 e shows a conventional activation process in the proper alignmentof the conventional stretch laminate;

FIG. 4 a shows another exemplary, conventional stretch laminate havingcontinuously applied adhesive above and below the elastic film;

FIG. 4 b shows a conventional activation process with the properalignment of the conventional stretch laminate of FIG. 4 a;

FIG. 5 a is a cross-sectional view of a stretch laminate in accordancewith the present invention;

FIG. 5 b shows the novel stretch laminate of FIG. 5 a with particularemphasis on the adhesive applied laterally outboard of the elastic film;

FIG. 5 c shows the novel stretch laminate of FIG. 5 a with particularemphasis on the adhesive applied near the lateral ends of the elasticfilm;

FIG. 5 d shows the novel stretch laminate of FIG. 5 a with particularemphasis on the adhesive applied laterally in board of the ends of theelastic film;

FIG. 5 e shows a cross-sectional view of an exemplary activation processin the proper alignment of the novel stretch laminate of FIG. 5 a;

FIG. 6 a shows an exemplary manufacturing process in accordance with thepresent invention;

FIG. 6 b shows an exemplary adhesive applicator which may be used in themanufacturing process of FIG. 6 a;

FIG. 6 c shows a side elevational view of the slot of adhesiveapplicator within FIG. 6 b;

FIG. 6 d shows an exploded view of the slot within FIG. 6 c;

FIG. 6 e is a schematic of the adhesive deposition pattern from that ofthe plurality of shims which are included in the adhesive applicator ofFIG. 6 d;

FIG. 6 f is a schematic, cross-sectional view of the adhesive depositionpattern of FIG. 6 e;

FIG. 6 g shows a first and second web of nonwoven material havingadhesive applied in accordance with the present invention; a first andsecond elastic film is positioned interposed between said first andsecond web of nonwoven material in accordance with the presentinvention;

FIG. 6 h shows another exemplary shim design for a slot of an adhesiveapplicator in accordance with the present invention;

FIG. 6 i is a schematic of the adhesive deposition from that of theplurality of shims which are included in the adhesive applicator of FIG.6 h;

FIG. 6 j is a schematic, cross-sectional view of the adhesive depositionof FIG. 6 i;

FIG. 6 k shows a first and second web of nonwoven material havingadhesive applied in accordance with the present invention; a first andsecond elastic film is positioned interposed of said first and secondweb of nonwoven material;

FIG. 7 a shows another exemplary manufacturing process in accordancewith the present invention; this particular exemplary process includesthe application of additional adhesive layers; and

FIG. 7 b is a cross-sectional view of another exemplary, novel stretchlaminate made from the process of FIG. 7 a in accordance with thepresent invention.

DETAILED DESCRIPTION OF THE INVENTION Definitions:

The term “absorbent article” herein refers to devices which absorb andcontain body exudates and, more specifically, refers to devices whichare placed against or in proximity to the body of the wearer to absorband contain the various exudates discharged from the body, such as:incontinence briefs, incontinence undergarments, absorbent inserts,diaper holders and liners, feminine hygiene garments and the like.

The term “disposable” is used herein to describe absorbent articleswhich generally are not intended to be laundered or otherwise restoredor reused as absorbent articles (i.e., they are intended to be discardedafter a single use and, preferably, to be recycled, composted orotherwise discarded in an environmentally compatible manner).

The term “diaper” herein refers to an absorbent article generally wornby infants and incontinent persons about the lower torso.

The term “pant”, as used herein, refers to disposable garments having awaist opening and leg openings designed for infant or adult wearers. Apant may be placed in position on the wearer by inserting the wearer'slegs into the leg openings and sliding the pant into position about thewearer's lower torso. A pant may be preformed by any suitable techniqueincluding, but not limited to, joining together portions of the articleusing refastenable and/or non-refastenable bonds (e.g., seam, weld,adhesive, cohesive bond, fastener, etc.). A pant may be preformedanywhere along the circumference of the article (e.g., side fastened,front waist fastened). While the term “pant” is used herein, pants arealso commonly referred to as “closed diapers”, “prefastened diapers”,“pull-on diapers”, “training pants” and “diaper-pants”. Suitable pantsare disclosed in U.S. Pat. No. 5,246,433, issued to Hasse, et al. onSep. 21, 1993; U.S. Pat. No. 5,569,234, issued to Buell et al. on Oct.29, 1996; U.S. Pat. No. 6,120,487, issued to Ashton on Sep. 19, 2000;U.S. Pat. No. 6,120,489, issued to Johnson et al. on Sep. 19, 2000; U.S.Pat. No. 4,940,464, issued to Van Gompel et al. on Jul. 10, 1990; U.S.Pat. No. 5,092,861, issued to Nomura et al. on Mar. 3, 1992; U.S. patentapplication Ser. No. 10/171,249, entitled “Highly Flexible And LowDeformation Fastening Device”, filed on Jun. 13, 2002; U.S. Pat. No.5,897,545, issued to Kline et al. on Apr. 27, 1999; U.S. Pat. No.5,957,908, issued to Kline et al on Sep. 28, 1999, the disclosure ofeach of which is incorporated herein by reference.

The term “machine direction (MD)” or “longitudinal” herein refers to adirection running parallel to the maximum linear dimension of thearticle and/or fastening material and includes directions within ±45° ofthe longitudinal direction.

The term “cross direction (CD)”, “lateral” or “transverse” herein refersto a direction which is orthogonal to the longitudinal direction.

The term “joined” encompasses configurations whereby an element isdirectly secured to another element by affixing the element directly tothe other element, and configurations whereby an element is indirectlysecured to another element by affixing the element to intermediatemember(s) which in turn are affixed to the other element.

The term “interposed” herein means to place or introduce somethingbetween two or more other things.

The term “controllable” herein means a having such precision so as toachieve a tolerance 10% or less, preferably 5% or less. As it relates toadhesive application, being “controllable” means that the target amountof adhesive to be applied is achieved within a tolerance of 10% or less(preferably 5% or less) in the CD direction. As discussed herein, onenovel technique includes the use of a plurality of adhesive supplieswhich are designated to a plurality of shims within the slot of theadhesive applicator.

Description:

FIG. 5 a shows a cross-sectional view of a stretch laminate 199 inaccordance with the present invention. Stretch laminate 199 comprises afirst web of nonwoven material 110 and a second web of a nonwovenmaterial 112. Further, laminate 199 includes at least one elastic film130 positioned in between said first and second nonwoven materials. Inaddition, at least two planes of adhesive are applied within saidlaminate. For instance, a bottom plane of adhesive is shown havingcontinuous and discontinuous regions. More specifically, regions ofadhesive which are located laterally outboard of said elastic film 130is identified as adhesive 120 n. Regions of adhesive which are locatedlaterally in board of said elastic film 130 are identified as adhesive120 f. Lastly, regions of adhesive which are located laterally near theends of elastic film 130 are identified as adhesive 120 t. Similarly, asecond plane of adhesive may be provided having continuous anddiscontinuous regions. More specifically, regions of adhesive which arelocated laterally outboard of said elastic film 130 are identified asadhesive 121 n. Regions of adhesive which are located laterally in boardof said elastic film 130 are identified as adhesive 121 f. Lastly,regions of adhesive which are located laterally near the ends of elasticfilm 130 are identified as adhesive 121 t.

FIG. 5 b shows the stretch laminate 199 of FIG. 5 a with particularemphasis on the adhesive located laterally outboard of elastic film 130.These particular areas of interest are identified by brackets labeled“N”. The amount of adhesive applied within these regions is constrainedby two competing interests. First, too much glue within these regionswill cause adhesive to bleed through said first and second nonwovenmaterials. Secondly, not enough glue within these regions will result inpoor lamination between said first and second nonwoven materials. As canbe seen, elastic film 130 does not extend between adhesive 120 n andadhesive 121 n such that the amount of adhesive exposed to eithernonwoven material is effectively doubled in quantity. Recognizing suchfact, however, one cannot merely reduce the amount of adhesive within120 n and 121 n because doing so would affect the amount of adhesiveabove and below elastic film 130. Such competing interests add to thecomplications of the present invention.

FIG. 5 c shows the stretch laminate 199 of FIG. 5 a with particularemphasis on the adhesive located laterally near the ends of elastic film130. These particular areas of interest identified by brackets labeled“T”. The amounts of adhesive applied within these regions are similarlyconstrained by concerns of bleed through and insufficient lamination.Furthermore, the amount of adhesive 120 t, 121 t should be properlymaximized so as to provide tackdown functionality for that of elasticfilm 130. As can be seen, it is often preferable to provide moreadhesive within these regions (i.e., tackdown) than that of the amountsupplied within the regions 120 n, 121 n. The novel designed of themanufacturing equipment within the present invention allows for suchdifferences and the amount of adhesive applied within these regions.

FIG. 5 d shows the stretch laminate 199 of FIG. 5 a with particularemphasis on the adhesive located laterally and board to the ends ofelastic film 130. These particular areas of interest are identified bybrackets labeled “F”. The amounts of adhesive applied within theseregions are similarly constrained by concerns of bleed through andinsufficient lamination. Furthermore the amount of adhesive 120 f, 121 fshould be properly minimized so as to permit the laminate to properlystretch during activation (EG, ring rolling); otherwise, the presence oftoo much adhesive will result in pinholes within said laminate. Thenovel design of the manufacturing equipment within the present inventionallows for continuous and/or discontinuous application of adhesive 120f, 121 f so as to have a amount which is less than that of tackdownadhesive 120 t, 121 t, respectively.

FIG. 5 e shows an exemplary activation process in accordance with thepresent invention. As can be appreciated, the region which issubstantially in board of tackdown adhesive 120 t, 121 t is aligned withthe teeth of activation roll 180, 182. In this way, the area of largeamounts of adhesive (EG, tackdown adhesive 120 t, 121 t) may bepreserved after activation.

FIG. 6 a shows a schematic of an exemplary manufacturing process 2000 inaccordance with the present invention. A first web of nonwoven material110 is supplied in a direction as indicated by arrow 111. Adhesive 120is applied to said first nonwoven 110 by way of an adhesive applicator122. A second web of nonwoven material 112 is supplied in a direction asindicated by arrow 113. Adhesive 121 is applied to said second nonwoven112 by way of an adhesive applicator 123. A web of elastic film 130 issupplied in a direction as indicated by arrow 131. These three webs ofmaterials are sandwiched together between combining rolls 170, 172. Saidcombining rolls rotate in a direction as indicated by arrows 171, 173,respectively. Once these three webs of materials are sandwichedtogether, they are subsequently activated between activation rolls 180,182. Said activation rolls rotate in a direction as indicated by arrows181, 183, respectively. Activation of said webs by way of activationrolls 180, 182 is sometimes referred to as “ring rolling”. After saidactivation, the resulting product is a stretch laminate 199.

FIG. 6 b shows an exemplary applicator adhesive 122 from that of FIG. 1a. Adhesive applicator 122 may comprise of a manifold 124, a pluralityof adhesive inlets 125 a-c and a slot 126. Referring now to FIG. 6 c,slot 126 may comprise of a backplate 127, a plurality of shims 128 and afrontplate 129. Referring now to FIG. 6 d, an exploded view of slot 126is shown. As can be seen, backplate 127 may comprise of a plurality ofadhesive inlet ports 127 a, 127 b and 127 c. Adhesive may be introducedinto slot 126 through said adhesive inlet ports. In this particularembodiment, adhesive inlet 125 a is in fluid communication with adhesiveinlet ports 127 a. The same is true for adhesive inlets 125 b and 125 cwith adhesive inlet ports 127 b and 127 c, respectively. Said adhesivemay then exit through corresponding adhesive outlet ports, whereupon theadhesive will come into contact with a plurality of shims 128. Shims 128may consist of multiple portions including a closed portion 128 c, anopen portion 128 t for deposition of tackdown adhesive 120 t, an openposition 128 n for deposition of nonwoven adhesive 120 n and apartitioned portion 128 f for deposition of film adhesive 120 f. In thismanner, separate adhesive supplies may be provided to the variousportions so as to properly provide predictable and differing amounts ofadhesive in accordance with the present invention.

FIG. 6 e shows the exemplary shims 128 from that of FIG. 6 d. Further,exemplary depositions of adhesive are shown having exited through shims128. For instance, adhesive intended to be placed between said first andsecond nonwoven materials and also laterally outboard of elastic film130 is identified as 120 n. Additionally, adhesive intended to be placedbetween said first and second nonwoven materials and also near theoutboard edges of elastic film 130 is identified as 120 t. Finally,adhesive intended to be placed between said first and second nonwovenmaterials and also laterally positioned inboard the edges of elasticfilm 130 is identified as 120 f. Referring now to FIG. 6 f, across-sectional view of the adhesive deposition patterned from FIG. 6 eis shown. As can be appreciated from this cross-sectional view, theadhesive within the region intended to be placed above or below elasticfilm 130 is discontinuous while the adhesive in the other regions iscontinuous. Further, the amount of tackdown adhesive 120 t is greaterthan the amount of nonwoven adhesive 120 n. Unlike conventionalapparatus, the adhesive applicator design of the present inventionprovides separate adhesive supplies to the various portions so as toproperly provide predictable and differing amounts of adhesive inaccordance with the present invention.

FIG. 6 g shows the first web of nonwoven material 110 having regions ofadhesive. For example, a full coverage of adhesive 120 n is applied inthe areas surrounding the subsequent placement of elastic film 130. Inthe areas which will be underneath the subsequent placement of elasticfilm 130, a partial coverage of adhesive 120 f is applied. In thisparticular example, a series of parallel lines of adhesive is applied.Similar to the first web of nonwoven material 110, the second web ofnonwoven material 112 also has regions of adhesive. For example, a fullcoverage of adhesive 121 n is applied in the areas surrounding thesubsequent placement of elastic film 130. In the areas which will beunderneath the subsequent placement of elastic film 130, a partialcoverage of adhesive 121 f is applied. In this particular example, aseries of parallel lines of adhesive is applied. As is also shown inthis conventional embodiment, two webs of elastic film 130 are alignedwith said parallel lines of adhesive 120 f, 121 f. Partial applicationof adhesive in this manner is important because these regions will besubjected to ring rolling as discussed above; therefore, these regionsof material must be sufficiently elastic so as not to create pinholes.The areas of full coverage 120 n, 121 n will not be significantlyactivated, rather these areas of full coverage provide for maximumadherence of first and second nonwoven materials. A full coverage oftackdown adhesive 120 t of greater amount than that of nonwoven adhesive120 n is applied in near the longitudinal edges of the subsequentlyplaced elastic film 130.

FIG. 6 h shows another exemplary slot 226 comprising of a backplate 227,a plurality of shims 228 and a frontplate 229. As can be seen, backplate227 may comprise of a plurality of adhesive inlet ports 227 a, 227 b and227 c. Adhesive may be introduced into slot 226 through said adhesiveinlet ports. In this particular embodiment, adhesive inlet 225 a is influid communication with adhesive inlet ports 227 a. The same is truefor adhesive inlets 225 b and 225 c with adhesive inlet ports 227 b and227 c, respectively. Said adhesive may then exit through correspondingadhesive outlet ports, whereupon the adhesive will come into contactwith a plurality of shims 228. Shims 228 may consist of multipleportions including a closed portion 228 c, an open portion 228 t fordeposition of tackdown adhesive 220 t, an open position 228 n fordeposition of nonwoven adhesive 220 n and an open portion 228 f fordeposition of film adhesive 220 f. In this manner, separate adhesivesupplies may be provided to the various portions so as to properlyprovide predictable and differing amounts of adhesive in accordance withthe present invention.

FIG. 6 i shows the exemplary shims 228 from that of FIG. 6 h. Further,exemplary depositions of adhesive are shown having exited through shims228. For instance, adhesive intended to be placed between said first andsecond nonwoven materials and also laterally outboard of elastic film230 is identified as 220 n. Additionally, adhesive intended to be placedbetween said first and second nonwoven materials and also near theoutboard edges of elastic film 230 is identified as 220 t. Finally,adhesive intended to be placed between said first and second nonwovenmaterials and also laterally positioned inboard the edges of elasticfilm 230 is identified as 220 f. Referring now to FIG. 6 j, across-sectional view of the adhesive deposition patterned from FIG. 6 iis shown. As can be appreciated from this cross-sectional view, theadhesive within the region intended to be placed above or below elasticfilm 230 is continuous and having a deposition amount less than that oftackdown adhesive 220 t. Further, the amount of tackdown adhesive 220 tis greater than the amount of nonwoven adhesive 220 n. Unlikeconventional apparatus, the adhesive applicator design of the presentinvention provides separate adhesive supplies to the various portions soas to properly provide predictable and differing amounts of adhesive inaccordance with the present invention.

FIG. 6 k shows the first web of nonwoven material 210 having regions ofadhesive. For example, a full coverage of adhesive 220 n is applied inthe areas surrounding the subsequent placement of elastic film 230. Inthe areas which will be underneath the subsequent placement of elasticfilm 230, a full coverage of adhesive 220 f is applied but in an amountless than the amount of tackdown adhesive 220 t. Similar to the firstweb of nonwoven material 210, the second web of nonwoven material 122also has regions of adhesive. For example, a full coverage of adhesive221 n is applied in the areas surrounding the subsequent placement ofelastic film 230. In the areas which will be underneath the subsequentplacement of elastic film 230, a full coverage of adhesive 221 f isapplied but in an amount less than the amount of tackdown adhesive 221t. As is also shown in this novel embodiment, two webs of elastic film230 are aligned with said lesser amount of adhesive 220 f, 221 f. Lesserapplication of adhesive in this manner is important because theseregions will be subjected to ring rolling as discussed above; therefore,these regions of material must be sufficiently elastic so as not tocreate pinholes. The areas of full coverage 220 n, 221 n will not besignificantly activated, rather these areas of full coverage provide formaximum adherence of first and second nonwoven materials. A fullcoverage of tackdown adhesive 220 t of greater amount than that ofnonwoven adhesive 220 n is applied in near the longitudinal edges of thesubsequently placed elastic film 230.

FIG. 7 a shows another schematic of an exemplary manufacturing process3000 in accordance with the present invention. A first web of nonwovenmaterial 310 is supplied in a direction as indicated by arrow 311. Afirst adhesive 320 a is applied to said first nonwoven 310 by way of anadhesive applicator 322 a. A second adhesive 320 b is also applied tosaid first nonwoven 310 by way of an adhesive applicator 322 b. A secondweb of nonwoven material 312 is supplied in a direction as indicated byarrow 313. A first adhesive 321 a is applied to said second nonwoven 312by way of an adhesive applicator 323 a. A second adhesive 321 b is alsoapplied to said second nonwoven 312 by way of an adhesive applicator 323b. A web of elastic film 330 is supplied in a direction as indicated byarrow 331. These three webs of materials are sandwiched together betweencombining rolls 370, 372. Said combining rolls rotate in a direction asindicated by arrows 371, 373, respectively. Once these three webs ofmaterials are sandwiched together, they are subsequently activatedbetween activation rolls 380, 382. Said activation rolls rotate in adirection as indicated by arrows 381, 383, respectively. Activation ofsaid webs by way of activation rolls 380, 382 is sometimes referred toas “ring rolling”. After said activation, the resulting product is astretch laminate 399.

FIG. 7 b shows a cross-sectional view of a stretch laminate 299 inaccordance with the present invention. Stretch laminate 299 comprises afirst web of nonwoven material 210 and a second web of a nonwovenmaterial 212. Further, laminate 299 includes at least one elastic film230 positioned in between said first and second nonwoven materials. Inaddition, at least four planes of adhesive are applied within saidlaminate. For instance, a first-bottom plane of adhesive is shown havingcontinuous and discontinuous regions. More specifically, regions ofadhesive which are located laterally inboard of said elastic film 230are identified as adhesive 220 f and regions of adhesive which arelocated laterally near the ends of elastic film 230 are identified asadhesive 220 t. A second plane of adhesive is shown having continuousregions of adhesive which are located laterally outboard of said elasticfilm 230 and are identified as adhesive 220 n. Similarly, a third planeof adhesive is shown having continuous regions of adhesive which arelocated laterally outboard of said elastic film 230 and are identifiedas adhesive 221 n. Lastly, a fourth-top plane of adhesive may beprovided having continuous and discontinuous regions. More specifically,regions of adhesive which are located laterally inboard of said elasticfilm 230 are identified as adhesive 221 f and regions of adhesive whichare located laterally near the ends of elastic film 230 are identifiedas adhesive 121 t. Laminate 299 may be made from the manufacturingprocess of FIG. 7 a. Alternatively, the increased amount of adhesivewithin the tackdown region may be accomplished by overlapping a firstdeposition for the film adhesive and a second deposition for thenonwoven adhesive. An additional benefit of overlapping said depositionsis the assurance that no significant gap (i.e., absence of adhesive) ispresent in the laminate thus resulting in a weak spot in the laminate.

Product Applications

One skilled in the art would appreciate that the stretch laminates ofthe present invention may be used in a multitude of applicationsincluding, but not limited to, disposable absorbent articles, bodywraps, clothing, feminine hygiene products, and bandages. However, it isparticularly beneficial for disposable absorbent articles, morespecifically with respect to its use in the construction of a waistregion and/or fastener.

All documents cited are, in relevant part, incorporated herein byreference; the citation of any document is not to be construed as anadmission that it is prior art with respect to the present invention.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

For example, one skilled in the art would appreciate that the number ofmultiple shims and the number of multiple adhesive supplies may bevaried to meet the particulars of a given situation and need.

Additionally, one skilled in the art would also appreciate that theelastic film may be applied discontinuously (e.g., via a cut and slipdevice) to either the first and/or second nonwoven material, or appliedto another nonwoven web (e.g., carrier web) which is ultimatelyinterposed between the first and second nonwoven materials.

Additionally, one skilled in the art would also appreciate that eithercontact or non-contact adhesive applicators may be used.

Additionally, one skilled in the art would also appreciate thatdiscontinuous application (e.g., film adhesive deposition) of adhesivemay be accomplished in the CD and/or MD directions.

Additionally, while slot coat adhesive applicators were primarilydiscussed herein, one skilled in the art would appreciate that othertypes of adhesive applicators may be used to accomplish the noveldeposition designs disclosed herein. Such applicators include, but arenot limited to, gravure applicators and spray applicators.

Additionally, one skilled in the art would appreciate that increasedamounts of adhesive may be applied when the stretch laminate is to beaffixed to another material. For example, when the stretch laminate is atab portion within a disposable diaper needing to be affixed to achassis, an increased amount of adhesive may be used to impartadditional strength in this bond.

What is claimed is:
 1. A stretch laminate comprising: a first nonwovenmaterial; a second nonwoven material; an elastic film, said elastic filmbeing interposed between said first and second nonwoven materials, saidelastic film having a first longitudinal side edge and a secondlongitudinal side edge, wherein portions of said first and secondnonwoven materials extend laterally outboard of said first and secondlongitudinal side edges of said elastic film; a first plane of adhesivehaving differing amounts of adhesive as measured laterally within thestretch laminate, said first plane of adhesive being interposed betweensaid first nonwoven material and said elastic film; a second plane ofadhesive having differing amounts of adhesive as measured laterallywithin the stretch laminate, said second plane of adhesive beinginterposed between said second nonwoven material and said elastic film;wherein at least one of said first plane of adhesive or said secondplane of adhesive comprises: a first portion of adhesive being laterallylocated between said first and second longitudinal side edges of saidelastic film, said first portion of adhesive being defined as filmadhesive; a second portion of adhesive being laterally located near atleast one longitudinal side edge of said elastic film and inboard ofsaid at least one longitudinal side edge, said second portion ofadhesive being defined as tackdown adhesive; and a third portion ofadhesive being laterally located outboard of said longitudinal sideedges of said elastic film to adhere the portions of the first nonwovenmaterial extending laterally outboard of the first and secondlongitudinal side edges of said elastic film to corresponding portionsof the second nonwoven material extending laterally outboard of thefirst and second longitudinal side edges of said elastic film, saidthird portion of adhesive being defined as nonwoven adhesive; whereinthe tackdown adhesive is present in an amount greater than an amount ofthe film adhesive and greater than an amount of the nonwoven adhesive;wherein the film adhesive is discontinuous, the tackdown adhesive iscontinuous, and the nonwoven adhesive is continuous; wherein the elasticfilm is applied discontinuously between said first and second nonwovenmaterial; wherein each of the above elements being substantiallylaminated together to form a laminate; and wherein said laminate isactivated to form the stretch laminate.
 2. The stretch laminate of claim1, wherein the other of said first plane of adhesive or said secondplane of adhesive comprises: a first portion of adhesive being laterallylocated between said first and second longitudinal side edges of saidelastic film, said first portion of adhesive being defined as filmadhesive; a second portion of adhesive being laterally located near atleast one longitudinal side edge of said elastic film, said secondportion of adhesive being defined as tackdown adhesive; and a thirdportion of adhesive being laterally located outboard of saidlongitudinal edges of said elastic film, said third portion of adhesivebeing defined as nonwoven adhesive.
 3. The stretch laminate of claim 2,wherein said nonwoven adhesive has an application amount less than thatof said tackdown adhesive.
 4. The stretch laminate of claim 1, whereinsaid laminate is activated in a cross direction of said laminate.
 5. Thestretch laminate of claim 4, wherein the laminate is activated betweenthe longitudinal side edges of said elastic film.
 6. The stretchlaminate of claim 1, wherein at least one of the tackdown adhesive, thefilm adhesive and the nonwoven adhesive are applied using a sprayapplicator.
 7. A stretch laminate comprising: a first nonwoven material;a second nonwoven material; an elastic film, said elastic film beinginterposed between said first and second nonwoven material, said elasticfilm having a first longitudinal side edge and a second longitudinalside edge, wherein portions of said first and second nonwoven materialsextend laterally outboard of said first and second longitudinal sideedges of said elastic film; a first plane of adhesive, said first planeof adhesive being interposed between said first nonwoven material andsaid elastic film; a second plane of adhesive, said second plane ofadhesive being interposed between said first nonwoven material and saidelastic film, wherein said first and second plane of adhesive havediffering amounts of adhesive from each other as measured laterallywithin the stretch laminate; a third plane of adhesive, said third planeof adhesive being interposed between said second nonwoven material andsaid elastic film; a fourth plane of adhesive, said fourth plane ofadhesive being interposed between said second nonwoven material and saidelastic film, wherein said third and fourth plane of adhesive havediffering amounts of adhesive from each other as measured laterallywithin the stretch laminate; wherein said first and fourth planes ofadhesive comprise: a first portion of adhesive being laterally locatedbetween said first and second longitudinal side edges of said elasticfilm, said first portion of adhesive being defined as film adhesive; anda second portion of adhesive being laterally located near at least onelongitudinal side edge of said elastic film and inboard of said at leastone longitudinal side edge, said second portion of adhesive beingdefined as tackdown adhesive; wherein said second and third planes ofadhesive comprise of adhesive being laterally located outboard of saidlongitudinal side edges of said elastic film to adhere the portions ofthe first nonwoven material extending laterally outboard of the firstand second longitudinal side edges of said elastic film to correspondingportions of the second nonwoven material extending laterally outboard ofthe first and second longitudinal side edges of said elastic film, saidsecond and third planes of adhesive being defined as nonwoven adhesive;wherein the tackdown adhesive is present in an amount greater than anamount of the film adhesive and greater than an amount of the nonwovenadhesive; wherein at least one of said first plane of adhesive, saidsecond plane of adhesive, said third plane of adhesive, or said fourthplane of adhesive is applied through an adhesive applicator having aplurality of shims designated for application of said film adhesive,said tackdown adhesive, and/or said nonwoven adhesive; wherein the filmadhesive is discontinuous, the tackdown adhesive is continuous, and thenonwoven adhesive is continuous; wherein the elastic film is applieddiscontinuously between said first and second nonwoven material; whereineach of the above elements being substantially laminated together toform a laminate; and wherein said laminate is activated to form thestretch laminate.
 8. The stretch laminate of claim 7, wherein saidlaminate is activated in a cross direction of said laminate.
 9. Thestretch laminate of claim 8, wherein the laminate is activated betweenthe longitudinal side edges of said elastic film.
 10. The stretchlaminate of claim 7, wherein at least one of the tackdown adhesive, thefilm adhesive and the nonwoven adhesive are applied using a sprayapplicator.
 11. A stretch laminate comprising: a first nonwovenmaterial; a second nonwoven material; an elastic film; said elastic filmbeing interposed between said first and second nonwoven material, saidelastic film having a first longitudinal side edge and a secondlongitudinal side edge, wherein portions of said first and secondnonwoven materials extend laterally outboard of said first and secondlongitudinal side edges of said elastic film; a first plane of adhesivehaving differing amounts of adhesive as measured laterally within thestretch laminate, said first plane of adhesive being interposed betweensaid first nonwoven material and said elastic film; a second plane ofadhesive having differing amounts of adhesive as measured laterallywithin the stretch laminate, said second plane of adhesive beinginterposed between said second nonwoven material and said elastic film;wherein at least one of said first plane of adhesive or said secondplane of adhesive comprises: a first portion of adhesive being laterallylocated between said first and second longitudinal side edges of saidelastic film, said first portion of adhesive being defined as filmadhesive; a second portion of adhesive being laterally located near atleast one longitudinal side edge of said elastic film and inboard ofsaid at least one longitudinal side edge, said second portion ofadhesive being defined as tackdown adhesive; and a third portion ofadhesive being laterally located outboard of said longitudinal sideedges of said elastic film to adhere the portions of the first nonwovenmaterial extending laterally outboard of the first and secondlongitudinal side edges of said elastic film to corresponding portionsof the second nonwoven material extending laterally outboard of thefirst and second longitudinal side edges of said elastic film, saidthird portion of adhesive being defined as nonwoven adhesive; whereinthe tackdown adhesive is present in an amount greater than an amount ofthe film adhesive and greater than an amount of the nonwoven adhesive;wherein the film adhesive is discontinuous in a cross direction, thetackdown adhesive is continuous in a cross direction, and the nonwovenadhesive is continuous in a cross direction; wherein at least one of thefilm adhesive, the tackdown adhesive and the nonwoven adhesive arediscontinuous in a machine direction; wherein each of the above elementsbeing substantially laminated together to form a laminate; and whereinsaid laminate is activated to form the stretch laminate.
 12. The stretchlaminate of claim 11, wherein said laminate is activated in a crossdirection of said laminate.
 13. The stretch laminate of claim 12,wherein the laminate is activated between the longitudinal side edges ofsaid elastic film.
 14. The stretch laminate of claim 11, wherein atleast one of the tackdown adhesive, the film adhesive and the nonwovenadhesive are applied using a spray applicator.